Apparatus for welding metal



Feb. lo, y R. H. DYER APPARATUS FOR WELDING METAL Filed Sept. ll, 1940 5 SlleebS-Sl'leec(y l m n r N 'QM A lNvEN-roR ATToNll-:Y

Feb. 1o, 1942. R, H- DYER 2,272,968

APPARATUS FOR WELDING METAL Filed Sept. 11`, 1940 5 Sheets-Sheet 2 INVENTOR MW B ATTORNEY Feb. 10, 1942. R. H. DYER APPARATUS FOR WELDING METAL Filed Sept. ll, 1940 5 Sheets-Sheet 3 INVENTOR ex /z er.'

ATTORNEY Feb. 1o, 1942'. Rf H YER 2,272,968

APPARATUS FOR WELDING METAL ATTORNEY Feb. 10, 1942. R, H. DYl-:R

APPARATUS FOR WELDING METAL Filed Sept. 1l, 1940 5 Sheets-Sheet 5 Patented Feb. 10, 1942 UNITED STATES PATENT OFFICE APPARATUS Foa WELDING METAL Application September 11, 1940, Serial No. 356,362

7 Claims.

This invention relates to apparatus for electrically welding metal, and has for its principal object to effect a weld through passage of an electrical current from the face side of a work piece and to effect penetration of the current through the part which is to be weldingly connected therewith whereby the entire welding operation may be effected exteriorly of an assembled or partly assembled structure.

Another object of the. invention is to provide means for striking the metal with a hammer-like blow at the time of the Weld to bring the. parts into rm contact and improve texture and strength of the weld.

Further objects of the invention are to provide means for effecting a surge of the welding current and intensifying the voltage thereof subsequent to initial heating of the metal tobe welded; to provide means for choking the current iiow through one of the electrodes whereby the welding heat is concentrated at the contact and striking point of the other-electrode; to provide electrodes that are self-adjusting relatively to the work; to provide means for cooling the electrodes; and to provide-a simple control mechanism for latching and tripping the percussion device utilized in effecting the hammer-like blow at the time of the weld.

In accomplishing these and other objects of the invention, I have provided improved details of structure, the preferred form of which is illustrated in the accompanying drawings, wherein:

Fig. l is a perpective view of a portable hand Welder constructed in accordance' with the present invention and adapted for carrying out my improved method of welding.

Fig. 2 is an enlarged detail perspective view of the electrodes.

Fig. 3 is a longitudinal section through the Welder showing the electrodes, the percussion device or hammer parts, and control switch in their normal non-welding positions.

Fig. 4 is a similar view, partly in elevation, showing the electrodes applied to the work, and the hammer being moved from cocked toward tripping position7 the current control switch being in closed position.

Fig. 5 is a similar view showing the switch open and the percussion device tripped to effect impact of the heated weld.

Fig. 6 is a cross-section through the electrodes on the line 6 6 of Fig. 3, particularly illustrating cooling thereof.

Fig. 7 is a cross-section through the barrel of the Welder on the line 1 1 of Fig. 3.

Fig. 8 is a cross-section on the line v8 8 of Fig. 8.

Fig. 9 is a cross-section on the line 9-9 of Fig. 3.

Fig. 10 is a detail perspective view of the parts of the percussion mechanism in disassembled spaced relation.A

Fig. 11 is a diagrammatic view of the ends of the electrodes showing the path of the current therebetween. v

. Fig. 12 is a section through the electrodes and work piece showing the passage of the current.

Fig. 13 is a diagrammatic viewof the electric circuits supplying a welding current to the Welder.

Fig. 14 is a partial section through a modied form of electrodes.

Fig. 15 is a crosssection through the modified form of electrodes on the line I5-I5 of Fig. 14.

Fig. 16 is a digrammatic view of a modified form of circuit wiring. v v

Referring more in detail to the drawings:

I designates a Welder embodying the features of the present invention and adapted for welding in accordance with my improved method. The welder illustrated is of portable, hand-operated type, and is especially adapted for welding of assembled or partly assembled structures. The weld-er is of pistol shape and includes a substantially cylindrical shaped barrel 2 supporting electrodes 3-4 and a percussion or hammer mechanism 5. Depending from the barrelv 2 is a stock 6 for housing a control switch 'I, a switch operating toggle 8, and the electrical connections for supplying welding current to the electrodes as later described. The welder also includes a handle grip 9 for manipulation thereof and effecting pressure of the electrodes against the work for automatically closing the switch and cooking and tripping the percussion mechanism when effecting a weld, as later described.

The barrel.2, stock 6, and handle grip 9 are preferably formed by mating sections I0 and I I that are secured together by fastening devices such as screws I2 extending through one of the sections and threadedly engaging the other. Formed in the forward end of the barrel 2 is a bore I3, coaxially aligning with bores I4 formed in spaced, inwardly extending partitions I5 or I6,' the latter bores being bushed by suitable'insulating material I'I and I8 to insulate the elec'- trodes that are slidably carriedtherein, as clearly shown in Fig. 3, the electrode 3 preferably comprising an outer, sleeve-'like member that is snugly slidable in the bushings and which' extends freely through the bore |3 to carry a head I9 formed of a material having higher resistance than the body of the electrode and having a threaded neck engaging a threaded counterbore 2| in the outer endof the sleeve. 'I'he neck, including the adjacent portion of the head, has a bore 22, corresponding to the bore of the sleeve, and which cooperates with a smaller coaxial bore 23 to form an intermediate stop shoulder 24. The bore 23 extends through a reduced threaded terminal 25 on the forward portion of the head and threaded thereon is a ring 26 having substantially the same circumference as that of the head and sleeve. 'I'he head of the electrode is provided with a circumferential passageway 21 having inlet and outlet connections 28 and 29 with hose 30 and 3| which preferably lead through openings 32 in the forward end of the stock 6 to connect as at 33 and 34 with ducts l35 and 36 carried by the current conducting cables 21 and 38. A cooling medium, such as water, may be circulated through one of the ducts and the hose connected therewith through the passageway and returned through the hose to the other duct for cooling the electrodes and maintaining a desired temperature. Thev opposite end of the electrode projects within the portion of the barrel carrying the percussion mechanism as shown in Fig. 3.

The sleeve electrode 3 is lined with an insulating tube 39, and the bore portion 23 of the head I9 is lined with an insulating tube 40 that engages the forward end of the tube 39 to insulate the plunger electrode 4 which is slidably mounted therein. 'I'he plunger electrode.4 has a reduced terminal 4| at its forward end to form a shoulder 42 which` normally seats against the insulating tube and the opposite end projects from the sleeve electrode to mount a collar 43 carrying a depending rearwardly extending arm The collar 43 is insulated from the end of the sleeve electrode by an insulating washer 45. The electrode tip 4| is of substantially conical form and projects freely through the insulating tube to form a contact face 46 in spaced relation with the annular contact face 41 of the outer electrode when the electrodes are in the position shown in Fig. 3. The sleeve electrode is normally retained in projected position by a coil spring 48 that is sleeved over the insulating bushing I1 and has one end bearing against the bushing I8 and the other against pins 49 that are carried by the sleeve electrode and operating in slots 50 formed in the insulating bushing as clearly shown in Fig. 3.

The percussion mechanism 5 is carried by a socket member 5| that has a reduced threaded stud 52 threadedly engaged in an insulating bushing 53 which is mounted in an opening 54 formed in the end walls of the sections l0 and I'I, the insulating bushing 53 being provided with a flange 55 to space the socket member from the boss 56 surrounding the opening 54. The socket member 5I is interiorly threaded to mount a cylindrical hammer guide 51 ,which projects toward the electrodes and has its forward end carrying a cap 58. 'I'he cap 50 has a socket-like bore 59 extending forwardly through a reduced threaded neck 60 which threads into the forward end of the guide 51. The bore 59 terminates short of the forward end to provide a stop shoulder 6| circumferentially of an axial opening 62 in which is supported a drift 63 having afiangelike head 64 slidable within the socket-like bore 59 and adapted to engage the shoulder 8|. The

ver electrode 4. The bore of the cap is closed by a bushing 69 that is threaded therein to engage a spring 10 sleeved over a reduced, rearwardly extending stem r1| of the drift, and has its opposite end engaging against the flange 64 to retain the drift in projected position with the pilot engaging the end of the socket 66. The stem 1| projects through an opening 12 in the bushing and into an opening 13 formed in the forward end of a hammer 14. The hammer 14 is best illustrated in Fig. l0, and includes a cylindrical body 15 of suitable diameter to slidably engage within a reduced bore 16 in the rear end of the guide. The forward end of the hammer is supportingly retained on the stem 1| and is carried in an enlarged bore 11 of the guide which cooperates with the rear bore tov form an annular shoulder 18 which trips' the latch mechanism, now to be described. f

The latch includes a substantially cylindrical bolt 19 that is reciprocably mounted/in a transverse bore of the hammer 14, and which intersects the opening 13 so that the stern of the drift extends within the bore 80 into an opening 8| of the bolt 19. Formed on the rear end of the stem 1|is a reduced pilot 82 to provide an annular shoulder B3 that is adapted to normally engage against the upper edge 84 of the bore 80 in one position of the bolt where a slightly roundedend 85 thereof is engaged with the wall of the enlarged bore of the guide tube as shown in Fig. 3. The bolt is normally retained in this po sition by a leaf spring 86 fixed to a flattened face 81 of the bolt by a fastening device, such as a rivet 88. The forward end B9 of the spring has a lip which extends within the upper end of the bore 80 and engages the upper end of the bolt to yieldingly retain the bolt in the position shown in Fig. 3, with the shoulder B3 of the drift in latching engagement with the edge 84 of the bolt. The hammer is normally retained in forwardly projected position by a coil spring 9| having one end engaging against the bottom of the socket member 5| and its other end engaging against the rear end of the hammer` 14.

ACurrent is delivered to the electrodes through conductors 92 and 93 positioned within the cables 31 and 38 and having terminals 94 and 95 connected by exible leads 96 and 91 with the arm 44 of the plunger electrode and with the sleeve electrode respectively, the flexible connections being securedto the respective electrodes by fastening devices, such as cap-screws 98 and 99. The conductors are connected with a secondary winding |00 of a current transformer |0| which includes a primary winding |02 supplied with a suitable current through conductors |03 and |04 from a current supply service comprising the line wires |05 and |06. Inserted in the conductor |04 is a magnetically actuated relay switch |01 to automatically make and break circuit with the primary of the transformer. The conductor |04 is connected with the primary of the transformer by a contact arm |09 engageable with one of the taps of the secondary whereby the induced current in the secondary is selectively regulated to provide the proper welding current, as indicated by the ammeter |09 which is inserted in the conductor 93 and the voltameter ||0 which is connected across the conductors 92 and 93 as clearly shown in Fig. 3.

The switch |01 includes an electromagnet having a winding I I2 connected by conductors ||3 and ||4 with a low voltage circuit supplied through the line wires ||5 and H6. The circuit to the electric winding is automatically controlled by the switch 1.

This switch includes an insulating block ||8 that is fastened on the under side of the hammer guide and carries a leaf spring switch arm ||9, having a contact adapted to engage a contact |2| xed on the forward end of the block ||8. The -spring contact is connected with the control circuit by a terminal |22 and the fixed contact is connected in asimilar manner. 'I'he switch arm is moved into engagement with the xed contact by the toggle 8 which is pivotally mounted on a pin |24 carried by a yoke-shaped end |25 of the arm 44. The toggle 8 is preferably formed of insulating material and has a flat forward face |26 adapted to engage a stop face |21 of the arm 44 by pressure of a spring 8 when y the electrodes move in one direction and to swing away from the stop |21: against action of the spring 8 when the electrodes move in the opposite direction.v The toggle 8 projects upwardly above the arm and is engaged by an insulating block |28 carried by the switch arm I9 as shown in Figs. 3 to 5 inclusive.

In order to produce a surge in the current and increase the voltage at the time a weld is eiected,

the conductors 92 and 93 condenser |29.

The plunger electrode shown in Figs. 14 and 15 is substantiall; the same as that of the first form. However, the sleeve electrode carries a ball |30 to which a socket |3| is connected to universally carry the contact terminal |32. With this arrangement the work contact face |33 of the terminal |32 automatically adjusts itself to the work so that it engages around the entire periphery thereof.

Fig. 16 illustrates a three-phase circuit for supplying current to the Welder. In this instance the three line wires |34, |35 and |36 are connected by conductors |31, |38 yand |39, the conductor l|31 being connected with the adjustare connected by a able contact |40 of the transformer, and the conductor |38 with one of the end terminals of the primary and with a resistance winding |4| that is connected with the conductor |39. 'Ihe primary of the transformer thus operates in exactly the same manner as the primary previously described. However, 110 volts are applied across the resistance element |4| to supply a ground potential to the work piece through the conductor |42, the conductor |42 being connected by a suitable clamp indicated at |43. In order to vary the voltage of the ground circuit, the conductor |42 is connected with a contact |44 which is adapted to be adjusted along the resistance |4|. The ground circuit, being connected with the part of the work which is to be welded to the part engaged by the electrodes 'of the Welder, reduces tendency of the current tol flow directly across the electrodes and the welding current is caused to penetrate the upper plate and into the lower plates a greater distance toheat the metal to a welding temperature prior to striking of the hammer-like blow. In all other respects, the circuit is the same as that previously described, except that a three-pole relay switch are electively heated.

|45 is necessary to control flow of current through the conductors |31, |38 and |39.

. In using a Welder constructed and assembled as described, it is held by the handle 9 and stock,

and the work contact face of the plunger elec-A 1,] trode is brought into contact with the point of thei Pressure is then applied so that the sleeve electrode and supporting housing move forwardly against ac'- work pieces to be welded together.

, since the leaf spring is retaining the bolt 19 against the inner face of the hammer guide, the edge 84 is engaged by the annular shoulder 83 of the drift and the drift 63 holds the'hammer to compress and load the spring 10. As soon as the toggle lever |23 is engaged by the block |28, the switch arm |I9 is moved into circuit closing position relatively to the fixed contact |2| to close the circuit to the relay switch |01, thereby energizing the winding of the electromagnet and causing the switch to close the primary circuit of the transformer. A secondary current is then induced in the secondary winding |00 so that a welding current is completed through the work pieces to be welded together by way of the conductor 93, flexible lead 98, arm 44, collar 43, plunger electrode 4, and through the work contacting face 46, across the upper plate of the work and 4through the lower plate where it flows toward the annular work contact face of the sleeve electrode to heat the metal to welding temperature, the path of the current being indicated by the dotted lines a shown in Figs. 11 and 12.

` Owing to the fact that the head of the sleeve electrode is of higher resistance than that of the head of the plunger electrode, the ow of current is, in effect, partially blocked, and forced deeply through the metal so that both plates The major or highest heat is concentrated under the contact face of the plunger electrode and the weld takes place at this point. During initial energization of the primary circuit, the condenser |29 is loaded.

During heating of the metal the relative movev ment of the housing continues because of the applied pressure and the rounded end 85 of the bolt 19 soon rides over the shoulder 18 into the smaller portion of the bore. This movement causes the bolt to move upwardly so that the latch edge 84 thereof disengages from the shoulder of the drift, whereupon the hammer spring is effective to forcibly move the hammer into contact with the drift, imparting a hammerlike blow through the drift and the plunger electrode onto the work. This blow, being struck immediately after heating ofthe metal, brings the parts to be welded into contact and compensates for any irregularity in the metal that tends to hold them apart. The hammer-like blow also causes impaction of the heated metal and improves the strength and texture of the weld. At the time the hammer is being rendered effective, or while it is being moved into contact with the drift, the toggle lever rides off the insulation block |28 to open the circuit, thereby interrupting flow of welding current through the electrodes, and since the electrodes are still in contact with the metal the condenser unloads to effect a current surge through the metal. This may be timed to occur just prior to actuation of the hammer, or at ,the time the hammer isl ef- Iective.

When the Welder is removed fromcontact with the work, the springs restore` the electrodes tov their original position with relation to the hous- It is obvious that with a Welder constructed as described a weld can be made completely from the outside of an assembled or partly assembled i structure.

What I claim and desire to secure by Letters' Patent is: y

1. "A welding apparatus including, an electrode support, a pair of electrodes carried by the support and having movement relative vto the support when pressure 'is applied -to the e'lec' trodes through the support to bring said electrodes into engagement with the work vto be weld- Yed and to eiect movement of the support relative to the electrodes, a current supply connected with the electrodes, a switch controlling flow of current to the electrodes, means connecting the switch with one of the electrodes for effecting closure of the switch upon movement of the' sup,- port in bringing said electrodes into contact the work to effect -closure of the switch uponmovementof. the's-upport in bringing the other electrode into contact with the work, a spring--y loaded hammer carried by the support for effecting a hammer-'like blow on one of the electrodes, latch means engageable with the hammer upon movement ofA the support relatively to the electrodes to load said spring, and means for releasing the hammer against action of its loading `spring subsequent to closing of said switch.

4.' A welding apparatus including, a support,

a pair of electrodes carried by the support and having successive movement relative to the support when pressure is applied to -the electrodes through they support to bring the electrodes successively into engagement with the work to be welded and to' effect 'movement of the support relatively to the electrodes. means supplying currentrto the electrodes including a switch for controlling flow of current, means connecting the switch with the first electrode' to contact the work to effectclosure of the switch 'upon' movement of the support in bringing the other elecwith the work, a percussion means carriedby. the

support and engageable withone of the electrodes, and means for energizing the percussion means responsive to movement of the support in bringing saidelectrodes into contact with the work for striking the work subsequent to clo sure of the switch. i

2. A welding apparatus including, an electrod support, a pair of electrodes carried by'the support and having successive movement relative to the support when pressure is applied t0 the electrodes through the support to bring said electrodes successively into engagement, with the work to be welded and to effect movement of the support relatively to the electrodes, a current supply connected, with the electrodes, a

switch controlling flow of current to the electrodes, means connecting the switch with the first electrode to contact the work for eilecting closure of the switch upon movement of thev support in bringing the other electrode into contact with the work, percussion means carried by the support and engageablewith one of the electrodes, and means'for energizing the percussion means responsive to movement of the support relatively to said electrodes for striking the work subsequent to closure of the switch.

3. A `welding apparatus including, a support, a pair ot electrodes carried by the'support and having successive movement relative to, the support when pressure is applied to the electrodes through the support to bring the electrodes suctrode into contact with the work, a hammer carried by the support, a drift intermediate the hammerand one of the electrodes, a latch connecting'the drift with the hammer upon movement of the support relatively to the electrodes, a spring carriedv by the support for driving lthe hammer and loaded responsive to said movement of the support, and means arrangedv to release the hammer frompropelling influence of the drift to effect a blow of the hammer on saidl electrode responsive to unloading said spring.

5. A welding apparatus including, an' electrode s'upport,'a pair of electrodes carried by the support and having successive movement relative to the support whenpressure is applied to the electrodes through the support to bring said electrodes successively into engagement with the work to be weide@ and to effect movement of the support relatively. to the electrodes, a switch carried by the support, means supplying current to the ,electrodes through said switch, means connecting the switch with the first electrode to contact the work vto eii'ect closure of the switch upon movement of the support in bringing the other electrode into contact with the work, a hammer guide carried by the sup-port in axial alignment with the electrodes, a hammer slid able in the guide, a spi-ing urging the hammer in the directionl of the electrodes, a drift intermediate the hammer and one of the electrodes and having latch connection with the hammer to effect loading ofthe hammer spring upon movement of the support relatively to the electrodes, and means for tripping vsaid latch connection responsive to final movement of said support for en'ecting a hammer blow on the electrode through said drift.

6. A welding apparatus including an electrode support, a tubular electrode movably carried in the support, a rod-like electrode movable with; in the tubular electrode, compression springs retaining said electrodes in projected position with respect tok the electrode support and yieldable when pressure is applied to the support for bringing said electrodes into successive engagement with work to be welded and relative movement of the support on the electrodes, percussion means carried by the supportin axial alignment with the electrodes, means actuated by the movement of the support foi energizing theA percussion Ameans during initial movement of the support and for releasing the percussion means to strike a blow-on the work durin'g'nal movement of the support, and means supplying an electric current.

support and prior to release of the percussion,

means.

7. A welding apparatus including an electrode housing, a tubular electrode movably carried in the housing, a rod-like electrode movable within the tubular electrode, compression springs yield-v ingly retaining said electrodes. in projected position with respect to the housing whereby pressure on the housing brings said electrodes into successive engagement with work to be welded and relative movement of the housing on the electrodes, a hammer guide carried in the housing in axial alignment with the electrodes, a hammer slidable in the guide, a spring. urging the hammer in the direction of the electrodes,y

- moved relatively to the electrodes, means for revthe rod-like electrode.

leasing said bolt from the shoulder to release the hammer against action of the hammer spring, ,and means supplying an electric .current to the electrodes, said means being activated -responsive to initial movement of the housing relatively to REX H. DYER. 

